SPONSOR

ompressed Air Sponsors

US. Department of Energy

Northwest Energy Efficiency Alliance

New York State Energy Research and

Development Authority

NEES Companies

Iowa Energy Center

Illinois Department of Commerce and

Community Affairs

Honeywell, Inc.

Energy Center of Wisconsin

~

~ Eastern Utilities

Duke Solutions, Inc.

~ Consortium for Energy Efficiency

Compressor Distributors Association

Compressed Air and Gas Institute

Association of Ingersoll-Rand Distributors

By Floyd Barwig,

Compressed Air Challenge7’”

Advisory Board Chair

On behalf of the sponsors of the Com-

pressed Air ChallengeTM, it brings me great

pleasure to announce Fundamentals of Compressed Air Systems-a new training

on compressed air systems. This 1 -day

training is now available nationwide, with

workshops being offered in most major

cities (see insert). What makes this training

unique is the way it was developed, its

focus on system efficiency, and how it is

being offered across the country. The target

audience i s plant engineers and mainte-

nance supervisors, but anyone interested in

learning more about a systems approach i s

welcome to attend.

Fundamentals is the result of a remark-

able 2.5-year voluntary collaboration of the

best minds in the compressed air busi-

ness-users of compressed air, system con-

sultants, equipment manufacturers and

distributors, state and federal government,

an association of plant engineers, energy

efficiency organizations, and utilities. I have never been involved in anything quite

like this effort, which has brought together

so many different groups that share the

common goal of improving the perfor-

mance of industrial compressed air systems.

Raising awareness within US. industry

is what the Compressed Air ChallengeTM is

all about. That is, awareness about the

benefits of applying a ”best practices”

approach to the management of industrial

compressed air systems. The U.S. Depart-

ment of Energy estimates that these systems

use 90 billion IkWh per year. In most”

plants, 2O%&Y% of the energy used to

power these systems can be saved while

maintaining the same level of productivity.

This i s an overlooked opportunity to

reduce costs, improve system reliability,

and increase production capacity.

The Fundamentals training takes a com-

prehensive look at the compressed air

system, its various components and opera-

tional practices, and then assists partici-

pants in laying out seven steps to take in

order to identify and take advantage of

missed opportunities. Participants wil l

learn how to:

calculate energy costs of compressed air

improve compressed air system reliability

establish a baseline

match system supply to actual produc-

tion requirements

find leaks

attain better control of the compressed

air system

Each workshop is brought to you by

several organizations involved in develop-

ing the curriculum. They are taught by two

expert instructors drawn from a pool of 25 highly qualified and carefully selected

individuals. Every effort has been taken to

develop and present a curriculum that i s

technically accurate and product neutral.

As a package, the training i s an interactive

learning experience for both the student

and instructor. The focus is on giving partic-

ipants information that they can take back

to the plant and immediately put to use.

To learn more about the Compressed

Air ChallengeTM and how to participate,

please contact the Web site at www.

knowpressure.org, or call (800) 862-2086

for a registration form for a training work-

shop near you.

Compressed Air ChallengeIM 1

a m The Fundamentals of

Coinpressecl Air Sys-

tems training program is

designed to prepare the

participant to develop

aiid follow a seven-step

action plan. The pur-

pose of the action plan

i s to produce results-

lower operating costs

and greater reliability.

.......................................................................... '.*.*................*.........................~.........*...... Working to improve Compressed air systems are used to per-

form a variety of functions in businesses

and industries throughout the United

States. Though sometimes overlooked, a

properly designed and maintained coni-

these publications i s the Compressed Air &

Gas Handbook. The handbook provides a

wealth of information about compressed

air systems and compressed air equipment

that wi l l answer most questions posed by

pressed air system can play a

big part in making a business

successful. The Compressed

Air & Gas Institute (CAGI), a

non-profit trade association of manufacturers of components

of compressed aii systems, has

been working to improve the

end users. A companion video

series is being developed to

provide information about

compressed air systems in an

easily understood manner.

In addition to educational

publications, CAGl has devel-

oped a number of standards to

performance of compressed air systems

and equipnient in the United States for

over 80 years. End users can rely on the

expertise within CAGl and the standards

and educational material produced by the

institute to properly select equipment,

improve equipment reliability, and

enhance productivity.

Air Challenge'r" aiid has played a leading

role in providing technical support. CAGl

also i s a DOE Motor Challenge Allied

Partner.

Tools and Resources to Help You Improve Efficiency

CAGl members work to improve the

effectiveness of compressed air systems

and to increase the satisfaction of users of

compressed air systems with those systems.

The institute has developed many publica-

tions that address compressed air systems

and system components, including coni-

pressors, filters, tools, and dryers. Among

2 Compressed Air ChallengeThl

CACl is a sponsor of the Compressed

help end users specify the equipment that

wi l l provide the performance that they

need. CAGl standards deal with all aspects

of compressed air systems, including meth-

ods for testing and rating the performance

of various types of filters, dryers, and com-

pressors; compressor noise emission test

standards; and pneumatic tool safety

codes. The standards are intended to aid

end users in the selection of equipment,

and purchasers are advised to specify and

buy equipinent that has been tested to

CAGl standards.

The following CAGl projects also

address compressed air system effective-

ness and efficiency:

a common means of reporting perfor-

mance through standardized data sheets

that wi l l allow purchasers to more eas-

ily compare products. Data sheets for

rotary screw compressors and two types

of compressed air dryers have been

developed and wil l be implemented

this year Data sheets for other types of

compressors, filters, and blowers are

forthcoming

a searchable database wil l become

active this fall The database wil l be

a~cessible via the Internet and wil l (on-

tain the information found on the stan-

dard data sheets

development with DOE of an educd-

tional video on compressor selection

The video wil l complement the series of

videos that the institute has been pro-

ducing to address proper selection,

installation, and maintenance of com-

pressed air systems and components

co-hosting the Fundamentals of Com-

pressed Air Systems training sewons

that are being conducted by the Coni-

pressed Air Challenge'" this spring

continued active participation in the

work of the Compressed Aii Chal-

lenge'k", including promotion of train-

ing sessions and development of a more

advanced training curriculum

CAGl in collaboration with the Com-

pressed Air ChallengeTp1, the Motor Chal-

lenge Program, and other organizations

plays a part in improving the competitive-

ness of US. businesses by enhancing the

performance of compressed air systems, a

critical but sometimes overlooked factor in

the success of many businesses.

For more information about the Com-

pressed Air & Cas Institute, visit the CAGl

Web site at www.cagi.org.

Arizona Phoenix

California Los Angeles San Diego

Colorado Denver

Connecticut Hartford

Florida Jacksonville Tampa

Georgia Atlanta

Idaho Boise

Illinois Roc kford Peoria Chicago

Iowa Cedar Rapids Des Moines

lowa/lllinois Quad Cities

Kansas Kansas City

Mary I and Baltimore

Massachusetts Worchester Boston

Michigan Detroit

Minnesota Minneapolis

Missouri St. Louis

Montana Missoula

611 7/99

411 5/99 611 1/99

5/6/99

5/26/99

5/4/99 612 2/51 9

6/4/99

511 8/99

4/9/99 411 3/99 4/20 and 412 1 199

6/7/99 6/8/99

512 5/99

611 5/99

5/21/99

411 3/99 61419 9

6/3/99

412 819 9

411 5/99

412 819 9

Mesa Pavilion Hilton

Radisson Hotel Town & Country Resort & Conference

Doubletree Hotel

Northeast Uti I ities

Holiday Inn Airport Ramada Airport Inn & Conference Center

Wyndam Garden Buckhead

Doubletree Hotel Downtown

Holiday Inn Rockford Pere Marquette ComEd Technical Training

Kirkwood Community College Des Moines Area Community College

Eastern Iowa Community College

Best Western Inn and Conference Center

Sheraton

Ramada Inn Worchester Four Points Sheraton

Hyatt Regency Dearborn

Doubletree Hotel Minneapolis Airport at the Mall

Edwardsville, Southern Illinois University Facility

Holiday Inn Missoula

New Jersey Woodbridge

New York Buffalo SyracuseIAl ban y New York City

Oklahoma Oklahoma City

Ohio Cleveland

Oregon Portland

Pennsylvania Allentown Philadelphia Pittsburgh Yorl</Lancaster

Rhode Island Providence

South Carolina Greenville

Tennessee Knoxvi Ile Nashville

Texas Dallas San Antonio

Utah Salt Lake City

Virginia Richmond

Washington Spokane Seattle

Wisconsin Eau Claire Green Bay Janesville Madison Wau kesha

512 5/99

511 8/99 6/8/99 611 1/99

612 219 9

5/4/99

511 8/99

511 2/99 61419 9 6/8/9 9 611 019 9

511 1/99

6/11/99

511 3/99 5/28/99

5/28/99 611 4/99

5/26/99

611 1/99

511 1/99 61919 9

511 1/99 511 8/99 512 419 9 512 519 9 6/9/9 9

Sheraton Hotel at Woodbridge Place

Buffalo Marriott Radisson Plaza Syracuse LaGuardia Sheraton

Biltmore Hotel

Cleveland East Marriott

Oregon Institute of Technology

Days Inn & Conference Center Holiday Inn Valley Forge Holiday Inn Pittsburgh Airport Holiday Inn Visitor’s Center

Holiday Inn Downtown

Hilton Towers Creenville

H i Iton Knoxvi I le Airport Renaissance Marriott Nashvi I le

Dallas Marriott Quorum Doubletree San Antonio

Hilton Salt Lake City

Hilton Richmond Airport

Cavanaugh’s River Inn Spokane Radisson Hotel Seattle Airport

Quality Inn Comfort Suites Ramada Inn Dane Co. Expo Center Country Inn

For more information or a registration form, call (800) 862-2086

timi rm f its

Through a partnership with Detroit Edison,

Ford Motor Land Services embarked on a

project to improve the efficiency of the

compressed air systetn at its Woodhaven

Plant. Over the last year, Ford has imple-

mented a number of cost effective actions

at the plant that are resulting in improved

compressed air system performance and

cost savings.

Stamping Plant, located in Woodhaven,

Michigan, processes approximately 1,600 tons of steel per day into body panels for

Ford vehicles.

The 2.7 mi I I ion-square-foot Woodhaven

With a project team comprised of plant

management and skilled trade personnel,

Ford Motor Land Services and Detroit Edi-

son energy managers designed and imple-

mented a plan to reduce the plant's high

leakage rate and the $1 .8 million in elec-

tricity costs attributable to the compressed

air system. Empowering and involving two

experienced hourly machine repairmen,

Scott Brooks and Mike Rounsifer, was key

behind this effort. Their personal conimit-

nient and passion to I-educe compressed air

consumption has made this effort a success.

After just 6 months of effort, the plant

has reduced their average standard-cubic-

feet-per-minute (scfm) flow by approxi-

mately 18% (from 25,000 scfm to 20,500

scfm) and cut electricity costs by approxi-

mately $400,000 per year. One 800-hp

reciprocating compressor was taken com-

pletely off line and remaining in-service

compressors are consuming slightly less

energy.

Actions Implemented in the Second Half of 1998:

The Woodhaven plant undertook the fol-

lowing actions in its efforts to improve

compressed air system performance.

Assembled an Air Leak Detection/Cor-

rection team. Two machine repairmen

were assigned to identify and correct

significant leaks. Management support

was gained for this activity by present-

ing a cost-benefit analysis. Leak correc-

tion activities occur primarily during the

Ford Motor Land Services'2.7 million-square-foot Woodhaven Plant

~ f t e r just 6 months of effort, the plant has reduced their avera~e §tandard-

cubic-feet-per-minute (scfm) flow by approximately 18% (from 25,000 scfm to

~Q,500 scfm) and cut elec~ricity costs by ~ p p r o x i ~ a ~ e l y 00, 000 per year.

July and December plant shutdown,

during lunch breaks, and unscheduled

downtime. This effort is credited with

reducing air consumption approxi-

mately 2,500 SCFM (4,000,000 kWh).*

Replaced leaking seals on the stamping

press die automation valves, reducing

approximately 1000 SCFM (1,600,000

kWh).*

Lowered air header pressure approxi-

mately 5 psig, resulting in electrical sav-

ings of 2,300,000 kWh.*

Replaced existing flow measuring ori-

fice plates with low loss venturis to

measure discharge flow from two of the

largest air compressors. Replaced orifice

plate in main system header with an

averaging pitot tube.

Developed posters and banners to pub-

licize the leak detection/correction

effort with the production staff. This

year's budget includes funding to train

the production staff on the cost of air

and electricity and to continue to build

awareness.

Began shutdown of small (30 hp each)

dedicated satellite air compressors.

These satellite compressors were

installed to supply 11 0 psig compressed

air to some of the stamping press

robots. After testing, the team denion-

strated that five out of seven of these

compressors could be shutdown. Sup-

ply air for these robots was returned to

the plant's lower pressure (70 psig)

main air header. The need for the two

remaining satellite compressors is still

under evaluation. The projected energy

and maintenance savings for this pro-

ject is $sS,000 annually.

"We are very happy with the results we

have achieved so far from the improve-

ments we made to our compressed air sys-

tem. We want to continue to operate as

efficiently and cost effectively as possible,

so we have planned several efficiency

measures for this year," explains Joe

Ghislain of Ford Motor Land Services.

Actions being evaluated for 1999 include

refurbishing blanker die automation

valves, replacing leaking counter balance

pressure regulating valves, replacing air

driven vacuum pumps with electric vac-

uum pumps, correcting improper use oi'

compressed air, compressed air and electri-

cal departmental hilling, adding a part-

time electrician to the Air Leak Detection/

Correction Team, and installing energy-effi-

cient compressed air dryers and motors,

among other actions.

"Based on

1. 12 months of operation

2. Compressor hp average = 4.25 SCFM

(kW = 5.4 SCFM)

3. Electrical Power Cost: 0.0435 $/kWh

Comprcsscd Ail Challenge1hi 3

By J. Bruce Medaris, CPE, Executive Direcior, AFE

The level of knowledge among plant and facilities engineers regarding compressed air systems varies widely from 'expert' to none. The vast majority have very little knowledge of the high cost of this fourth utility, or what they can do to dramatically improve their operating efficiency. The Association for Facilities Engineering (AFE) entered into the Compressed Air Chal- lenge'rbl to help change this situation. The Challenge was conceived to educate industry about best practices in com- pressed air systems, through which sub- stantial energy savings could be realized.

AFE enthusiastically joined the Coni- pressed Air ChallengeT" under the auspices of the AFE Foundation, a not-for-profit organization representing about 9,000 plant and facilities engineers throughout

the country and abroad. It was, and is, the intention of the AFE Foundation to assure that the people responsible for the physical plant were educated as to the actions they could take to make better, more efficient use of their compressed air systems. AFE is dedicated to the proposition that the plant/facilities engineer is the linchpin con- necting upper management to the realities of operating and maintaining the physical plant. They are the people who are charged with operating and maintaining their plants as efficiently as possible within the mission and goals of the company.

The compressed Air ChallengeTbf is seen as a means of delivering the required level of knowledge on best practices for compressed air systems in a standardized format and content to all who need it.

Challenge'rM Project Development Com- AFE holds a seat on the Compressed Air

mittee in the interest of obtaining the best possible compressed air training content and quality for the engineers they repre- sent. In addition, AFE is looking forward to

a process of certification in compressed air systems as a means of providing a standard of reference for dealings between and among those involved in compressed air audits of plants, distributors, and plant per- sonnel. (AFE currently certifies plant engi- neers and plant maintenance managers.)

Conducting the compressed air training is a sensible decision for both financial and technological reasons, but for AFE, the Challenge presents an opportunity to immerse its members in an environment committed to education, in keeping with the AFE mission: "To Learn, Lead, and Influence."

....................................................................................................................................... The Compressor Distributors Association and the ompressed Air Challenge'" The formation of the compressed Air Chal- lengeTh1 spurred the creation of the Com- pressor Distributors Association by bringing together several independent compressor distributor associations Distributors for Atlas Copco, CompAir LeROI, Cardner Denver, Quincy and Sullair pooled their resources and formed the Association

Manufacturers' distributor organizations from across the nation represent the largest resource pool available to help form and

lengel" goals The several hundred pri- vately-owned compressor distributorships, along with their sales force, are the back-

bone of the compressor industry They rep- resent the compressor industry to the vast majority of coinpressed air users

The service departments of local com- pressor distributors have technicians avail- able to adjust contiols and verify proper performance of the components in a nor- mal compressed air system In most cases, their sales force are the individuals who wil l advise the users on supply equipment, system design, and proper uses for an

classrooms and eagerly learning the con- cepts developed These same people are the ones who wil l be filling future class- rooms with the industry users, their cus- tomers, in order to further these energy saving guidelines The involvement and support of the Compressor Distributors Association i s and wil l be crucial in the marketing, training and implementation of the Compressed Air ChaIlengelb1 The Compressor Distributors Association

of the Compressed Air ChallengeIM and i s pleased to be playing a part in its success

implement the Compressed Air Chal- energy-efficient system embraces the concepts and future thinking I

As the Compressed Air ChallengelM begins its first rollout training sessions, it is

the local distributors who are filling the I

I ....................................................................................................................................... DOE Supports Systems Approach to Compressed Air

Improvements to major fluid systems (pumps, fans, and air compressors sent up to 62% of potential savi manufacturing plants, as re US. Industrial Electric Mo t ket Opportunities Assessme efficiency opportunities are a systems approach-evalu from input power to the wo by the system. DOE'S Offic Technologies (DOE/OIT) began with the industrial compressed air in 1995 to identify possible joint projects

4 Compressed Air CliallengeTM

to encourage a systems approach to com-

pressed Air ChallengeTM, initi- y DOE/OiT, the American Energy-Efficient Economy,

nter of Wisconsin, is in OE/OIT's mission of part-

ry, and other government mental organizations. The

ciency and competitiveness of significantly improve the

ial5 and process industries. DOEIOIT has partnered with the Com-

I

pressed Air Challenge'M to develop the publication Improving Compressed Air Sys- tem Performance: A Sourcebook for Indus- try. The Sourcebook is available for $1 9.95 by calling (800) 862-2086.

As a sponsor of the Compressed Air ChallengeTM, DOE is excited to be partici- pating in a national rollout of the Funda- mentals o f Compressed Air Systems Training this spring. A listing of the training sites i s enclosed. Call (800) 862-2086 for a registration form. Please register early, as demand i s expected to be high.